Vehicle radiator

ABSTRACT

A vehicle radiator with a plurality of flat tubes, fins, two tube plates having an upright continuous edge and collars around tube plate openings soldered to tube ends, and two collecting tanks. The tanks have a continuous edge protrusion with a recess, the upright edge of the tube plates being bent into the edge protrusion. A continuous seal protrusion on the edge protrusion of the collecting tanks and supported on the flat tube plates define a space between the collecting tanks and the tube plates about their periphery or, alternatively, an insert is provided in the tube plates and includes an edge strip soldered on one side to the tube plate upright edge and a member supporting the inside of the edge protrusion. A seal is between the tube plate and the collecting tank.

CROSS REFERENCE TO RELATED APPLICATION(S)

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

TECHNICAL FIELD

The present invention is directed toward heat exchangers, and moreparticularly to vehicle radiators having tubes between tube plates andplastic collecting tanks.

BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIORART

Vehicle radiators having flat tubes, corrugated ribs and tube plateswith an upright continuous edge and with openings that match thecross-section of the flat tubes, into which the ends of the flat tubesdischarge are well known in the art. In many such radiators, the plateopenings are designed with collars to which the tube ends are soldered,and with plastic collecting tanks that are fastened mechanically ontheir edge protrusion to the edge of the tube plates with insertion of aseal, the edge of the tube plates being bent onto the edge protrusion ofthe collecting tanks by clamping.

A vehicle radiator with these features is known, for example, from FIG.2 of DE 34 40 489 C2, which has only one essentially flat tube platewith a collecting tank on one end of the flat tubes, with the flat tubeshaving an elongated connector so that the cooling water on the other endof the flat tube is deflected and flows back to the collecting tank.Ordinarily, for clamping of the collecting tank on the tube plate, acontinuous groove is formed in the tube plate in which the seal ismounted and therefore cannot slide, as is also shown in FIG. 6 of DE 3440 489 C2, such tube plates therefore not being viewed as being designedessentially flat.

DE 100 16 029 A1 is another example of a structure in which the tubeplates are not essentially flat, as is EP 1 273 864 A2, which addressesthe desire to equip vehicle radiators with smaller core depths (depthsof the flat tubes and corrugated ribs) while minimizing the change inperiphery by providing a second tube plate or intermediate plate.However, use of metal collecting tanks may be relatively costly,particularly where additional functional elements are required of thetank by design considerations. Further, the edge of the collecting tankprotrudes beyond the core, and therefore requires more space for theradiator than required by the core.

Still further, in radiators in which the tank is clamped on a tubeplate, not only during clamping but also during operation of theradiator there are often problems because the wall of the collectingtank or the edge protrusion does not remain stable but falls inward orslides.

The present invention is directed toward overcoming one or more of theproblems set forth above.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a vehicle radiator is providedincluding a plurality of flat tubes with corrugated fins therebetween,two tube plates having an upright continuous edge, collars in the tubeplates around tube plate openings, the collars being soldered to ends ofthe flat tubes, and two plastic collecting tanks. The tanks have acontinuous edge protrusion with a recess therein, the upright edge ofthe tube plates being bent into the edge protrusion recess tomechanically fastened the collecting tanks to the tube plates. Acontinuous seal protrusion is on the edge protrusion of the collectingtanks and supported on the flat tube plates to define a space betweenthe collecting tanks and the tube plates about their periphery. A sealis in the defined space between the tube plate upright edge and thecollecting tank edge protrusion.

In one form of this aspect of the present invention, the edge protrusionrecess is substantially continuous and reinforced with connectorsarranged at intervals defining a series of compartments. In a furtherform, flanges are at intervals about the upright edge of the tubeplates, where the intervals correspond to the connector intervals.

In another form of this aspect of the present invention, tabs on thecontinuous edge protrusion are adapted to position the seal in therecess.

In yet a further form of this aspect of the present invention, a deviceis provided for clamping the collecting tank to the tube plate toproduce the vehicle radiator, wherein the tube plate includesprotrusions and the device includes first punches adapted to engage theedge protrusion recess of the tank to hold down the tank on the tubeplate, and second punches between the first punches and adapted to bendthe tube plate protrusions into the recess. In a still further form, thefirst and second punches engage the recess and the plate protrusionsrespectively from a direction perpendicular to tube plate.

In still another aspect of the present invention, a vehicle radiator isprovided, including a plurality of flat tubes with corrugated finstherebetween, two tube plates having a continuous upright edge, collarsin the tube plates around tube plate openings, the collars beingsoldered to ends of the flat tubes, and two plastic collecting tankshaving a continuous edge protrusion with a recess therein. The uprightedge of the tube plates is bent into the edge protrusion recess tomechanically fasten the collecting tanks to the tube plates. An insertin the tube plates includes an edge strip soldered on one side to thetube plate upright edge and a member supporting the inside of the edgeprotrusion A seal is between the tube plate and the collecting tank.

In one form of this aspect of the present invention, stops on the insertsupport the collecting tank edge protrusion.

In another form of this aspect of the present invention, crossconnectors between sides of the insert support the collecting tank edgeprotrusion.

In still another form of this aspect of the present invention, deformededge strips on the insert support the collecting tank edge protrusion.

In yet another form of this aspect of the present invention, a groove isprovided in the tank edge protrusion, and the other side of the insertedge strip is received in the groove.

In still another form of this aspect of the present invention, the tankedge protrusion is supported in a groove in the insert edge strip. In afurther form, the insert edge strip groove has an inner wall and anouter wall, and the outer wall is secured to the tube plate uprightedge.

In yet another form of this aspect of the present invention, protrusionson the other side of the insert edge strip engage tube plate openings tosecure the insert part in the tube plate.

In a still further form of this aspect of the present invention, thecollars are aligned in the direction of the flat tubes and the tubeplates are flat.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-5 are perspective cutaway views of the connection of acollecting tank and flat plate of a vehicle radiator according to afirst aspect of the present invention;

FIGS. 6-28 variously illustrate a second aspect of the presentinvention, where:

FIGS. 6-7 illustrate one embodiment of pre-attachment of a tank andplate;

FIGS. 8-9 illustrate another embodiment of pre-attachment of a tank andplate, with FIG. 9 being a cross-sectional view along line 9-9 of FIG.8;

FIGS. 10-12 illustrate various embodiments of an insert part usable withthe present invention;

FIG. 13 is a cross-sectional view illustrating another embodiment ofpre-attachment of a tank and plate;

FIGS. 14-16 variously illustrate collecting tanks which may be used withthe present invention;

FIG. 17 is a partial view and FIGS. 18-23 are cross-sectional views ofthe edge of a tube plate and the edge strips of various insert partsusable with the present invention;

FIG. 24 is a front view and

FIG. 25 a side view of an end of a charge air cooler with which thepresent invention may be used;

FIG. 26 is a top view of a tube plate of a coolant radiator, and

FIG. 27 is a top view of a tube plate of a charge air cooler, which maybe used in accordance with the present invention; and

FIG. 28 is a cross-sectional view of yet another embodiment illustratingthe edge of a tube plate and the edge strips of an insert part usablewith the present invention.

DETAILED DESCRIPTION OF THE INVENTION

A vehicle radiator 30 according to one embodiment illustrated in FIGS.1-5 may be constructed of a suitable cooling grate or core including aseries of flat tubes 32 and corrugated fins or ribs 34. Two tube plates36 include a plurality of openings 38 and are secured to opposite endsof the tubes 32 whereby the flow may occur through the plate openings 38and the tubes 32. The tube plates 36 are each connected to a collectingtank 40.

FIG. 1 shows a cutout of one side of the vehicle radiator 30 with onepart of a tube plate 36, with only two flat tubes 32 of the mentionedrow, with as many openings 38, and with part of the corrugated ribs 34arranged between the flat tubes 32 and traversed by the cooling air(dashed arrows). The openings 38 are formed with collars 42 facing theflat tubes 32 and corrugated ribs 34, onto which the ends of the flattubes 32 are tightly and firmly soldered. The ends of the flat tubes 32may end beneath the surface of tube plate 38 in order to keep thepressure loss of the cooling medium flowing through the flat tubes 32low (solid arrows).

Part of a collecting tank 40 is also apparent in FIG. 1. The tank 40 maybe produced from plastic in an injection molding process, and ismechanically fastened on its continuous edge protrusion 44 to thecontinuous deformed edge 46 of the essentially flat tube plate 38. Thedeformed edge 46 of the tube plate 38 is bent onto the edge protrusion44 of the collecting tank 40 by clamping. The opposite side of thevehicle radiator (not shown) is designed identically.

A continuous protrusion 50 on the edge protrusion 44 of the collectingtank 40 is supported on the flat tube plate 36 and defines a space 54 toaccommodate a seal 56 on the deformed edge 46 of tube plate 36. The seal56 in the practical example in its uncompressed condition has a roundcross-section which would protrude above the cross-section of the space54, and is broadly pinched during clamping so that the sealing effect isproduced by substantially filling the space 54 with the seal 56.

The openings 38 in the tube plates 36 extend on both ends roughly to thecontinuous protrusion 50 on the edge protrusion 44 of collecting tanks40 so that only a slight protrusion of the deformed edge 46 beyond theperiphery of the core (the flat tubes 32 and corrugated ribs 34) iscreated. It is apparent in FIGS. 1 and 2 that the protrusion 50 lying onthe flat tube plate 36 is arranged roughly perpendicular over one end ofthe openings 38. The other end of openings 38 and the opposite side ofthe collecting tanks 40 are not shown, but are designed identically,which is expressed by the “continuous” edge 46 of the tube plate 38 andthe “continuous” edge protrusion 44 of the collecting tank 40.

The edge protrusions 44 of the collecting tanks 40 are formed with arecess 60 into which the deformed edge 46 of the tube plates 36 engages.While the protrusion 50 on the bottom of edge protrusion 44 of thecollecting tanks 40 is formed, the recess 60 on the top of the edgeprotrusion 44 of the collecting tanks 40 is formed as a continuousgroove. The deformed edge 46 of the tube plate 36 engaging in recess 60requires bending of this edge 46 inward by much more than 90° so thatthe securing function of the deformed edge 46 relative to the wall ofcollecting tank 40 is satisfied. In the practical example, the edge 46was bent inward by about 130° from the vertical into the recess 60 ofthe edge protrusion 44. The collecting tank 40 has no other stop on thetube plate 36, since essentially flat tube plates 36 are provided.According to FIG. 1, the deformed edge 46 was fully bent into the recess60.

FIGS. 2 and 3 show a modification wherein the deformed edge 46 of thetube plates 36 are formed with protrusions 66 arranged at intervals.These protrusions 66 are bent into the recess 60 which, as is apparentfrom FIG. 3, may be divided into compartments 68 by means of connectors70. The connectors 70 lead to higher rigidity in the recess 60, whichcan therefore be designed with smaller wall thickness so that theprotrusion 72 above the core is further minimized.

A device for clamping the collecting tanks 40 with the tube plates 36can also be deduced from FIG. 3, and includes a forming punch 76alternates in series with a hold-down punch 78. The hold-down punches 78each engage in a compartment 68 of the recess 60 and hold the collectingtank 40 in the desired position. The forming punch 76 bends a protrusion66 on the deformed edge 46 into the adjacent compartment 68. (Only oneforming punch 76 and one hold-down punch 78 are depicted in FIG. 3). Inorder to satisfy its hold-down function, the hold-down punch 78 shouldbe active somewhat earlier in time than the forming punch 76. The devicemay be advantageously situated in a metal-forming machine indicatedfunctionally in FIG. 3 by reference number 80. Punches 76, 78 act atroughly right angles to flat tube plate 36 on the deformed edge 46 andthe edge protrusion 44.

It can be deduced from FIG. 4 that the vehicle radiator may be equippedwith a core of smaller depth (<T) without changes, for example, in theconnection between tube plate 36 and collecting tank 40. For thisreason, the collar 42 of a smaller opening 38′ in tube plate 36 isindicated with reference number 42′, which pertains to a core with thesmaller depth (<T). The greater depth is marked with >T in FIG. 4.

Tabs 84 may also be provided to ensure support desired positioning ofseal 56. The tabs 84 may be formed on the protrusion 50 of edgeprotrusion 44 of collecting tanks 40 at a spacing from each other (seeFIG. 4 and 5).

Reference will now be had to FIGS. 6-27, in which comparable componentsto those just described have been given reference numbers which areincreased by one hundred.

As is apparent from the partial views of FIGS. 24 and 25, the plasticcollecting tanks 140 have an air inlet or outlet connector 200 (only oneof the two collecting tanks is shown). The edge protrusion 144 of thecollecting tanks 140 is fastened to the edge 146 of the tube plates 136by clamping. The charge air cooler has a series of flat tubes 132 withcorrugated ribs 134 arranged in-between, and the tube plates 136 eachhave openings 138, each of which is provided with a collar 142, alignedwith the core.

The radiator also has a side part 204 on each narrow side, one of theside parts being apparent in FIGS. 24-25. In the practical examplesdescribed below, an insert part 210 is used, which is inserted into tubeplate 136, where different variants of the insert part 210 are shown inFIGS. 10-12.

The insert part 210 may advantageously be made from aluminum sheet bydeformation, and have differently configured edge strips 212 accordingto the different variants, which impart a frame-like configuration toinsert part 210. Cross-connectors 216 are provided in FIGS. 10-12between the two long sides of insert part 210 and its deformed edgestrip 212.

The cross-connectors 216 may advantageously improve the stability of theinsert part 210, and an effect in which the gas or liquid streams areguided may also be imparted by the cross-connectors 216 by appropriatedesign of the setting angle a (FIG. 12). The size of setting angle a canvary from cross-connector 216 to cross-connector 216 as a function ofthe position of the inlet or outlet connector 200. For this purpose, thecross-connectors 165 on both ends are only connected via a relativelynarrow and therefore rotatable connector 218 to the edge strips 212. Itshould be understood, however, that the cross-connectors 216 are anoption which may or may not be used within the broad scope of thepresent invention, and can also be dispensed with, for example, withsmaller radiator sizes.

Protrusions 220 may also be provided on the lower edge of the edgestrips 212, with the protrusions 220 passing into openings 224 in tubeplate 136. The protrusions 220 and openings 224 together may be used totemporarily secure the edge strips 212 in the tube plate 136 so that thesoldering process can be conducted (see FIGS. 8, 11, 27).

The same task with reference to pre-attachment may also be solved, forexample, in the practical example from FIG. 13, which shows a sectionthrough the clamping, by bent protrusions or legs 166 which act on theedge strips 212 of the insert part 210.

FIGS. 6-7 illustrate yet another example of suitable pre-attachment, inwhich cutouts 228 are provided at intervals on the edge of tube plate136 into which a protrusion 226 on the edge strip 212 is bent. Inaddition, the edge strip 212 of the insert part 210 is deformedgroove-like with inner and outer walls 230, 231 in this practicalexample. The seal 156 is inserted into this groove, on which the edgeprotrusion 144 of the collecting tank 140 can lie (not shown in FIGS.6-7). The outer wall of the groove or the edge strip 212 is soldered onthe inside to the edge 146 of the tube plate 136, and clamping can occuras repeatedly shown in the other figures.

Still another advantageous practical example is shown in FIGS. 8-9, inwhich the seal 156 is situated in a continuous recess of the edgeprotrusion 144 of the collecting tank 140. The seal 156 itself is arubber strip of roughly rectangular cross-section produced by extrusionand cut to the corresponding length. The recess in the edge protrusion144 has cross-sectional constrictions 232 arranged at intervals (seeFIG. 9). These serve to impart the corresponding support to the seal 156by clamping it there and, consequently, it cannot fall out of the recessduring assembly of the collecting tank 140, when the sealing effect isachieved by pressing the seal 156 against the edge strip 212 of theinsert part 210. On the inside, the edge protrusion 144 lies against thealready described cross-connectors 216 of the insert part 210 andtherefore cannot slide. In another practical example (not shown) thecross-connectors 216 omitted with only individual deformations in theinsert part 210 arranged in a row and serving as means to support theedge protrusion 144.

Still another structure which may be advantageously used to avoidsliding and to guarantee stability of the position of edge protrusion144 is the provision of a groove 236 in edge protrusion 144, into whichone edge or side of the edge strip 212 engages (FIGS. 17-20). Thispractical example requires a correspondingly adjusted deformation of theedge strip 212, as shown by the cuts in the mentioned figures. Such agroove may be omitted, as illustrated in FIGS. 13, 21 and 23, in whichcase the deformation of the edge strip 212 and the edge protrusion 144may be modified so that a support of the edge protrusion 144 on the edgestrip 212 is present.

FIGS. 14-16 particularly illustrate universal and cost-effectivecollecting tanks 140 which are made of plastic and may be advantageouslyused with the present invention. A partition 240 may be provided in theplastic collecting tank 140, whereby flow through the radiator can bechosen advantageously for specific applications. The seal 156 includes across-connection 242 on which the partition 240 lies during assembly ofthe collecting tank 140. Complete flow deflection can be achieved by anadditional insert part 244 beneath the partition 240 or cross-connection242.

Already-discussed FIGS. 17-23 are partial views or sections through theedge 146 of the tube plate 136 and the edge strips 212 of the insertpart 210 in different practical examples from which, among other things,the clamping is also apparent. As particularly shown in FIG. 17, theouter edge of the edge protrusion 144 has cutouts, which are providedwhere the protrusions 166 are present on the edge 146 of the tube plate136. Because of this, a somewhat smooth (i.e., continuous) connectionedge is obtained on the outside. The protrusions 166, as alreadydescribed above, are bent inward and produce the clamping although itshould be appreciated that, with this alternative, it is not necessaryto bend the protrusions 166 into the recesses since the stability of theposition of edge protrusion 144 here is produced by the other expedientsdescribed above.

FIGS. 21-23 and 26-27 illustrate yet another feature which may be usedto position the insert part 210 in the tube plate 136, with knobs orindentations 246 are embossed at intervals on the edge of the edge strip212 on the bottom of tube plate 136. A precise positioning of the insertpart 210 is achieved with this than might otherwise be possible becauseof the bending radius on the edge 146 of the tube plate 136.

FIGS. 26 and 27 each show the inside of an essentially flat tube plate136, with FIG. 26 showing the tube plate 136 of a coolant radiator andFIG. 27 showing the tube plate 136 of a charge air cooler. The openings138 for the ends of the flat tubes are apparent there as well as thedescribed knobs or indentations 246. The openings 168 accommodate theprotrusions 220 on the lower edge of the edge strip 212, and the edge146 of tube plate 136 is only bent (i.e., aligned). The tube plates 36,136 require no groove to accommodate the seal.

FIG. 28 shows another modified variant in which the collar 142 is formedon the openings 138 in the tube plate 136 facing the direction of thecollecting tank 140. The insert part 210 may be as previously describedin FIGS. 19-20.

It follows from the preceding description and from the figures that thepresent invention lead to a minimal and therefore tolerable protrusion72 of collecting tank 40, 140 above the core, and that the core itselfmay be further reduced in size further the at least some aspects of thepresent invention. Moreover, at least some aspects of the presentinvention permit provision of a cooling grate of smaller depth T. Inaddition, despite the essentially flat tube plates 36, 136, a stableposition of the wall of the collecting tank 40, 140 may be provided.

Further, vehicle radiators designed according to the present inventionmay be made with a conceivably small modification expense to a radiatorof a smaller block depth. More cost-effective production of the tubeplates required for this purpose with smaller openings may also beachieved, since this is possible in principle with the existing tubeplate die in which only the hole punch set for larger openingsintegrated in the die need be replaced with a hole punch set for smalleropenings.

Moreover, a vehicle radiator in which the openings extend to theprotrusion on the collecting tank requires a relatively smallincorporation space because the bulge of the edge protrusion of thecollecting tank beyond the flat tubes is conceivably small, since nospace-demanding groove is provided in the tube plates. In prior artdesigns, the groove is not only provided to accommodate the seal, butrepresents a stop for the edge protrusion of the collecting tank, whichtherefore cannot fall inward during the clamping process or duringoperation of the vehicle radiator. This function is otherwise providedby the present invention in that a recess is provided on the edgeprotrusion of the collecting tank into which the edge of the tube plateengages so that the collecting tank remains stable and cannot fallinward even though the tube plate is essentially flat (i.e., it has nocontinuous groove and no other essential deformations between theopenings that extend above the surface of the tube plate and could forma stop for the collecting tank).

In accordance with the present invention, falling inward of the edgeprotrusion or the wall of the collecting tank having the edge protrusionmay also be advantageously prevented during the clamping process throughappropriate configuration of the clamping tool.

Still other aspects, objects, and advantages of the present inventioncan be obtained from a study of the specification, the drawings, and theappended claims. It should be understood, however, that the presentinvention could be used in alternate forms where less than all of theobjects and advantages of the present invention and preferred embodimentas described above would be obtained.

1. A vehicle radiator comprising: a plurality of flat tubes with finstherebetween; two tube plates having an upright continuous edge; collarsin said tube plates around tube plate openings, said collars beingsoldered to ends of said flat tubes; two plastic collecting tanks havinga continuous edge protrusion with a recess therein, said upright edge ofthe tube plates being bent into the edge protrusion recess tomechanically fastened the collecting tanks to the tube plates; acontinuous seal protrusion on the edge protrusion of the collectingtanks and supported on the flat tube plates to define a space betweenthe collecting tanks and the tube plates about their periphery; and aseal in said defined space between said tube plate upright edge and saidcollecting tank edge protrusion.
 2. The vehicle radiator of claim 1,wherein said edge protrusion recess is substantially continuous andreinforced with connectors arranged at intervals defining a series ofcompartments.
 3. The vehicle radiator of claim 2, further comprisingflanges at intervals about the upright edge of the tube plates, saidintervals corresponding to said connector intervals.
 4. The device ofclaim 1, further comprising tabs on the continuous edge protrusionadapted to position said seal in said recess.
 5. A device for clampingthe collecting tank to the tube plate to produce a vehicle radiatoraccording to claim 1, wherein said tube plates include protrusions, saiddevice comprising: first punches adapted to engage said edge protrusionrecess of said tank to hold down said tank on said tube plate; andsecond punches between said first punches and adapted to bend said tubeplate protrusions into the recess.
 6. The device of claim 5, whereinsaid first and second punches engage said recess and said plateprotrusions respectively from a direction perpendicular to tube plate.7. A vehicle radiator comprising: a plurality of flat tubes with finstherebetween; two tube plates having a continuous upright edge; collarsin said tube plates around tube plate openings, said collars beingsoldered to ends of said flat tubes; two plastic collecting tanks havinga continuous edge protrusion with a recess therein, said upright edge ofthe tube plates being bent into the edge protrusion recess tomechanically fasten the collecting tanks to the tube plates; inserts insaid tube plates, said inserts including an edge strip soldered on oneside to the tube plate upright edge and a member supporting the insideof said edge protrusion; and a seal between said tube plate and saidcollecting tank.
 8. The vehicle radiator of claim 7, further comprisingstops on said insert supporting said collecting tank edge protrusion. 9.The vehicle radiator of claim 7, further comprising cross connectorsbetween sides of said insert, said cross connectors supporting saidcollecting tank edge protrusion.
 10. The vehicle radiator of claim 7,further deformed edge strips on said insert, said deformed edge stripssupporting said collecting tank edge protrusion.
 11. The vehicleradiator of claim 7, further comprising a groove in said tank edgeprotrusion, wherein said other side of said insert edge strip isreceived in said groove.
 12. The vehicle radiator of claim 7, whereinsaid tank edge protrusion is supported in a groove in said insert edgestrip.
 13. The vehicle radiator of claim 12, wherein said insert edgestrip groove has an inner wall and an outer wall, and said outer wall issecured to the tube plate upright edge.
 14. The vehicle radiator ofclaim 7, further comprising protrusions on the other side of the insertedge strip, said protrusions engaging tube plate openings to secure theinsert part in the tube plate.
 15. The vehicle radiator of claim 7,wherein said collars are aligned in the direction of the flat tubes andthe tube plates are flat.